Patterned anode for lithium-ion batteries

Abstract

Anodic materials for lithium ions batteries include a current collector and a superlattice disposed on at least a portion of the current collector, the superlattice comprising: alternating layers of an anode active material and an anode inactive material; and a plurality of channels that extend from the current collector through the alternating layers of anode active material and anode inactive material.

What is claimed is: 
     
       1. An anode for a lithium ion battery, the anode comprising:
 a current collector; and 
 a superlattice disposed on at least a portion of the current collector, the superlattice comprising:
 alternating and parallel layers of an anode active material and an anode inactive material; and 
 a plurality of channels that extend from the current collector through the superlattice, the channels having been formed in the alternating layers of the anode active material and the anode inactive material; 
 
 wherein the anode inactive material is an intermetallic material of any two or more selected from the group consisting of Cu, Mo, Bi, Ni, Fe, Ti, V, C, Mn, Co, Ni, Tc, Ru, Rh, Ag, Au, Pd, W, Y, Sc, Zr, Nb, Hf, Ta, and an oxide thereof. 
 
     
     
       2. The anode for a lithium ion battery of  claim 1 , wherein the current collector comprises copper, stainless steel, titanium, tantalum, platinum, gold, aluminum, nickel, cobalt, cobalt nickel alloy, highly alloyed ferritic stainless steel containing molybdenum and chromium, a nickel-containing alloy, a chromium-containing alloy, or a molybdenum-containing alloy. 
     
     
       3. The anode for a lithium ion battery of  claim 1 , wherein the current collector comprises a foil. 
     
     
       4. The anode for a lithium ion battery of  claim 1 , wherein the superlattice has a thickness of about 5 nm to about 5 μm. 
     
     
       5. The anode for a lithium ion battery of  claim 1 , wherein each of the plurality of alternating layers of the anode active material and the anode inactive material individually has a thickness of about 0.1 nm to about 150 nm. 
     
     
       6. The anode for a lithium ion battery of  claim 1 , wherein the anode active material is selected from the group consisting of Si, Zn, Sn, As, Sb, P, Cd, In, Mg, Ge, Al, S, Na, K, C, an oxide thereof, and a combination of any two or more thereof. 
     
     
       7. The anode for a lithium ion battery of  claim 6 , wherein the anode active material is Si. 
     
     
       8. The anode for a lithium ion battery of  claim 1 , wherein the superlattice comprises about 5 wt % to about 95 wt % anode active material. 
     
     
       9. The anode for a lithium ion battery of  claim 1 , wherein the plurality of alternating layers of an anode active material comprises a nanocrystalline structure. 
     
     
       10. The anode for a lithium ion battery of  claim 1 , wherein the plurality of alternating layers of an anode active material comprises an amorphous structure. 
     
     
       11. The anode for a lithium ion battery of  claim 1 , wherein the anode inactive material is selected from the group consisting of Cu, Mo, Ni, Fe, Ti, V, C, Mn, Co, Ni, Ru, Rh, Au, Pd, W, Y, Sc, Zr, Nb, Hf, Ta, an oxide thereof, and a combination of any two or more thereof. 
     
     
       12. The anode for a lithium ion battery of  claim 1 , wherein the intermetallic material is CuMo. 
     
     
       13. The anode for a lithium ion battery of  claim 1 , wherein the superlattice comprises about 95 wt % to about 5 wt % anode inactive material. 
     
     
       14. The anode for a lithium ion battery of  claim 1 , wherein the plurality of channels comprises a width of about 0.1 nm to about 10 nm. 
     
     
       15. The anode for a lithium ion battery of  claim 1 , wherein the plurality of channels allow diffusion of a non-aqueous electrolyte. 
     
     
       16. The anode for a lithium ion battery of  claim 1 , wherein the anode inactive material is an intermetallic material of any two or more selected from the group consisting of Cu, Mo, Ni, Fe, Ti, V, C, Mn, Co, Ni, Tc, Ru, Rh, Au, Pd, W, Y, Sc, Zr, Nb, Hf, Ta, and an oxide thereof. 
     
     
       17. A method for making an anode for a lithium ion battery, the method comprising:
 providing a current collector; and 
 depositing alternating and parallel layers of an anode active material and an anode inactive material and forming channels in the alternating and parallel layers after or during the depositing of the alternating layers to form a superlattice; 
 wherein:
 the anode inactive material comprises an intermetallic material having any two or more selected from the group consisting of Cu, Mo, Bi, Ni, Fe, Ti, V, C, Mn, Co, Ni, Tc, Ru, Rh, Ag, Au, Pd, W, Y, Sc, Zr, Nb, Hf, Ta, and an oxide thereof; and 
 the superlattice is disposed on at least a portion of the current collector. 
 
 
     
     
       18. The method of  claim 17 , wherein the superlattice is deposited using a physical vapor deposition method. 
     
     
       19. The method of  claim 18 , wherein the physical vapor deposition method comprises magnetron sputtering or electron beam evaporation. 
     
     
       20. The method of  claim 17 , wherein the anode inactive material is an intermetallic material of any two or more selected from the group consisting of Cu, Mo, Ni, Fe, Ti, V, C, Mn, Co, Ni, Tc, Ru, Rh, Au, Pd, W, Y, Sc, Zr, Nb, Hf, Ta, and an oxide thereof. 
     
     
       21. A lithium ion battery comprising:
 a non-aqueous electrolyte; 
 a cathode; and 
 an anode comprising:
 a current collector; and 
 a superlattice disposed on at least a portion of the current collector, the superlattice comprising:
 alternating, parallel layers of an anode active material and an anode inactive material; and 
 a plurality of channels formed into and extending that extend from the current collector through the alternating layers of anode active material and anode inactive material; 
 
 wherein the anode inactive material comprises an intermetallic material having any two or more selected from the group consisting of Cu, Mo, Ni, Fe, Ti, V, C, Mn, Co, Ni, Tc, Ru, Rh, Au, Pd, W, Y, Sc, Zr, Nb, Hf, Ta, and an oxide thereof. 
 
 
     
     
       22. The lithium ion battery of  claim 21 , wherein the anode inactive material is an intermetallic material of any two or more selected from the group consisting of Cu, Mo, Ni, Fe, Ti, V, C, Mn, Co, Ni, Ru, Rh, Au, Pd, W, Y, Sc, Zr, Nb, Hf, Ta, and an oxide thereof.